Safety hat suspension



March 1969 T. w. JOHNSON ETAL 3,430,260

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United States Patent 3,430,260 SAFETY HAT SUSPENSION Tom W. Johnson,Burton, Edward J. Stropkay, Cleveland,

and James D. White, Cleveland Heights, Ohio, assignors to SajarPlastics, Inc.

Filed Dec. 27, 1966, Ser, No. 604,920

U.S. Cl. 23 18 Claims Int. Cl. A42b 1/08 ABSTRACT OF THE DISCLOSURE Aresilient crown support for a hard shell safety hat having a firstsuspension with legs connected at their free ends to the shell, a secondseparate suspension within and beneath the first with an adjustable headband and integral straps, the straps being connected together at theirends below the first suspension and connected intermediate their ends tothe legs of the first suspension.

This invention relates to a safety hat, and more particularly to a crownsupport for a safety hat.

Typically, safety hats are constructed of a hard outer shell of strongmaterial, such as metal or plastic. The outer shell includes a crownsupport that covers the top of the wearers head. A crown support orsuspension, usually of straps, is secured within the shell and fitsdirectly over the wearers head. The suspension spaces the shell from thewearers head so that impacts upon the shell are cushioned.

The present invention is directed to a safety hat and novel crownsuspension of the general type mentioned in which a resilient, strongand readily adjustable suspension is provided of simple and economicconstruction.

Two separate suspensions are used in the present construction. A firstsuspension is connected directly to the inside of the hard shell andspaced from the top of the shell. A second suspension, located withinand below the first suspension, is removably secured to the firstsuspension. The two suspensions allow adjustment of the second or innersuspension independently of the first suspension attached to the shell.In addition, either suspension can be replaced without necessitating thereplacement of the other. The inner suspension and the first suspensionprovide a double spacing arrangement between the wearers head and thehard shell. The inner suspension is resilient to cushion impacts on theshell, while the first suspension is more rigid to prevent the shellfrom coming into contact with the inner suspension.

For strength, convenience, and economy, the second or inner suspensionthat directly engages the wearers head is formed of a head band that hasintegral head straps. The head band is formed of two flexible pieces toprovide an adjustment in size. The two pieces are arranged so theadjustment takes place symmetrically about a vertical, longitudinal,center plane of the hat. An improved construction permits thisadjustment without undesirable distortion of the head band or headstraps, even though the inner suspension is fixed at spaced points tothe first suspension, and even though the head straps and head band ofthe second or inner suspension are integrally formed. In the preferredconstruction, these parts are formed of suitable plastic by conventionalinjection molding techniques.

In order to enhance the effectiveness of the crown support in absorbingimpacts upon the outer shell, a simple yet effective resilientconnection is provided between the upper ends of the head straps of thesecond or inner suspension. This allows the upper portions of the headstraps that engage the top of the wearers head to expand,

stretching the resilient connection and absorbing the force of theimpact.

By way of a brief description, the first suspension is formed of legsthat radiate from a central circular portion. The free ends of the legsare attached to the inside rim portion of the hard outer shell. Exceptfor the attached ends, the first suspension is spaced from the innersurface of the hard shell.

The second suspension is formed of a circular head band and integral,upwardly extending, head straps. The head straps are securedintermediate their ends to the legs of the first suspension by studs.Upper ends of the head straps are looped through a large elastomericO-ring and fastened back upon themselves. The O-ring connects the headstraps beneath and spaced from the first suspension. Expansion of theupper ends of the head straps is permitted by the resiliency of theO-ring in response to an impact upon the safety hat. The expansion islimited by the legs of the first suspension, which overlie the headstraps.

The head band is formed of two separate pieces for adjustment. A largepiece encircles the front and sides of the wearers head and a smallpiece is at the rear of the hat. The ends of the two pieces areadjustably secured together. All but one of the head straps extend fromthe larger piece of the head band and are located forwardly of thecenter of the hat. A single head strap extends from the smaller headband piece at the center, rear, of the hat. Adjustments are made bymoving the smaller piece of the head band toward and away from the frontof the hat. Due to the location of each of the head straps, adjustmentsare made without changing the angular relationship of the head strapsrelative to the head band pieces. As a result, there is no undesirabledistortion of the band and straps, even though integrally formed.

It is an object, then, of this invention, to provide an improved safetyhat and double suspension crown support that is resilient and strong,adjustable, and which is convenient to assemble and economic tomanufacture. Other objects, features and advantages of this inventionwill become better understood with reference to the following detaileddescription, when considered along with the accompanying drawings, inwhich:

FIGURE 1 is a top plan view of a safety hat constructed in accordancewith the present invention, with parts broken away, showing a hard outershell and a crown support comprised of two suspensions;

FIGURE 2 is a transverse sectional view of the hat of FIGURE 1, takenalong the line 22 and looking in the direction of the arrows;

FIGURE 3 is a front elevational view of the hat of FIGURE 2, with partsbroken away and with parts in section;

FIGURE 4 is a plan view of a first suspension in a flattened condition,as formed;

FIGURE 5 is a transverse sectional view along the line 5-5 of FIGURE 4,looking in the direction of the arrows;

FIGURE 6 is a plan view of one of two flat pieces that form a head bandof the inner suspension, when assembled;

FIGURE 7 is a plan view of the second flat piece that forms the headband;

FIGURE 8 is a sectional view taken along the line 88 of FIGURE 7 andlooking in the direction of the arrows, and

FIGURE 9 is an elevational view of a stud used to assemble thesuspensions of the crown support.

Referring now to the drawings, an assembled safety hat 10 is shown inFIGURES l to 3, constructed in accordance with the present invention.The safety hat 10 consists of a conventional hard protective shell 12, afirst suspension 14 secured at spaced locations to the lower U portionof the shell, and a second suspension 16 secured to the firstsuspension. The second suspension is within and below the firstsuspension and adapted to directly engage the head of the wearer of thesafety hat.

The hard shell 12 of the safety hat includes a crown portion 18 and abrim 20, including a visor 21 at the front of the hat. A plurality ofspaced receptacles 24 are formed in the inside portion of the shell 12at the bottom of the crown 18, adjacent the brim 20. The receptacles 24are in the form of T-shaped slots open at the bottom and closed at eachside on the top. These receptacles receive portions of the firstsuspension 14 and secure the suspension within the hat against relativeupward movement with respect to the shell 12. As best shown in FIGURE 1,three of the receptacles 24 are located in the front half of the hat,i.e., forwardly of an imaginary transverse vertical plane passingthrough the center of the hat 10, as indicated by the line 25. Threereceptacles 24 are also located in the rear half. One receptacle 24 islocated at the center front of the hat, and one at the center rear ofthe hat.

The first suspension 14 is domed-shaped in assembly, as illustrated inFIGURES 2 and 3. It is flexible and strong, preferably formed ofsuitable plastic by injection molding techniques, and is initiallyformed in a fiat configuration, as illustrated in FIGURE 4. High densitypolyethylene has been determined after the testing and evaluation ofmany materials to have particularly suitable high and low temperaturecharacteristics of strength and lack of brittleness for this particularpurpose.

The first suspension 14 is of onepiece construction. It is formed of acircular center portion 26 and six legs 30a, b, c, d, e, f in the format narrow straps that radiate from the center portion 26. A circularcentral opening 31 is provided in the center portion 26. The radialspacing of the legs 30 corresponds with the locations of the receptacles24 of the shell 12. The leg 30a is located to cooperate with thereceptacle 24 at the center front of the shell 12, and the leg 30d withthe receptacle at the center rear. Legs 30b and 30f are located justforward of an imaginary center line indicated at 32 in FIGURE 4 and theremaining two legs 30c and 302 are located to the rear of the centerline 32.

Each leg 30 includes a generally rectangular foot portion 34. The footportions 34 are wider and thicker than the legs 30 to provide increasedstrength and rigidity. Two small projections 38 are formed on the flatouter surface of the foot portions 34, one adjacent each side edge. Theside edges of the foot portions 34 are received within vertical sidegrooves 37 of the T-shaped receptacles when the inner suspension 14 ispositioned within the shell 12, as shown in FIGURES 1 to 3. Theprojections 38 extend toward the inner surface of the shell 12 withinthe receptacles 24 and assure a snug fit of each foot in the respectivegroove. The side grooves 37 are blind at the top, preventing the footportions 34 from moving upward beyond the top of the associatedreceptacle 24. The legs 30 of the suspension 14 extend upward betweenthe verticle slot portions of the receptacles and curve to the center ofthe shell 12, spaced beneath the inner surface.

As illustrated in FIGURE 2, the foot portions 34 of the two side legs30b, 30 each include an extension formed of thick side edges 39 and athinner web 40 that extend below the foot portion when assembled in ashell. Two parallel slots 41 are formed in the web 40 of the two sidelegs 30b, 30 These slots receive the ends of a chin strap 42.

A small circular aperture 44 (FIGURE 4) is provided approximatelymid-way along the length of each leg 30 to facilitate connection of thetwo suspensions. Thus, apertures 44a, b, c, d, e, f are provided. Theseapertures 44 receive studs 46 that secure the second suspension to thefirst suspension, in a manner to be described subsequently. A secondaperture is provided adjacent each aperture 44 to provide foradjustment.

The second or inner suspension 14 is also dome-shaped when assembled. Itis initially formed flat in the configuration shown in FIGURES 6 and 7.The second suspension, like the first, is also a strap-like affair,preferably formed of strong flexible plastic by suitable injectionmolding techniques. A low density polyethylene is preferably used toprovide comfort since it has been found that the inner suspension doesnot need the strength of the outer suspension.

The second suspension 16 includes a two-piece head band 48 formed of alarger piece 48a shown in FIGURE 6, and a smaller piece 48b shown inFIGURE 7. The larger piece 48a of the head band 48 includes threeintegral head straps 50a, b, c. The smaller piece 48b of the head band48 includes a single integral head strap 51. The head straps extendupward from the head band pieces, essentially perpendicularly.

The two head band pieces 48a, 48b are constructed to be secured togetherat their opposite ends to form an adjustable, circular hand. To thisend, the piece 48a includes a small circular aperture 52 and anelongated slot 53 at one end and a similar aperture 54 and slot 55 atthe other end, arranged as shown in FIGURE 6. Bottom edges 56a, b andtop edges 57a, b of the head bands 48a, b, respectively, are curvedslightly upward to improve the configuration of the head band whenassembled.

As shown in FIGURE 7, the smaller piece 48b of the head band 48 has twoT-shaped guides 58 and 59. One is at each end and extends from the outersurface of the band portion, toward the shell 12, when assembled. Eachguide has a narrow leg portion 60 (see FIGURE 8) extending from the band48b. A wide cross portion 62 is secured to the leg, spaced from the band4812 a distance equal to the thickness of band 48a. A plurality ofspaced circular apertures 64 are formed in the piece 48b longitudinallyaligned adjacent the guide 58. A similar plurality of aligned apertures66 are located adjacent the guide 59.

When the two pieces 48a, 48b are joined together to form a circular headband, the opposite ends of the piece 48a are placed over opposite endsof the smaller piece 48b. The T-shaped guide 59 is pushed through theslot 55 by flexing the piece 48a to enlarge the slot. As best understoodfrom FIGURE 8, the leg portion 60 of each T-shaped guide is locatedwithin the respective slot of piece 481;, shown in phantom. The crosspiece 62 extends above and below the slot, along the outside of headband piece 48a.

In making any change in the size of the head band, both ends of the twopieces 48a, 48b are adjusted equally. The ends are moved so that theaperture 54 is aligned with a selected one of the apertures 66, and theaperture 52 is aligned with a corresponding one of the apertures 64. Astud 68 (see FIGURES 3 and 9) is inserted through each aperture 52, 54of the large head band piece 48a and also through the aligned apertures64, 66 of the small head band piece to retain the head band pieces inthe adjusted size.

The construction of the stud 68, which is identical to the stud 46 andother studs associated with the suspensions, is shown in FIGURE 9 of thedrawings. The stud includes a flat base portion 69 that is located atthe inside surface of the band 4812. A tapered head portion 70 isseparated from the fiat base 69 by a shank 71 of a length equal to thethickness of both head band pieces 48a, 48b. The head portion 70 istapered outwardly toward the base 69 to facilitate insertion through theapertures 64, 66 and to resist removal. The studs are preferably made ofa rigid and strong plastic, such as polycarbonate. By making the studsseparate from the suspensions they can be formed of stronger materialand can be replaced if broken. In addition this simplifies the moldconstruction used for molding the suspensions.

Each head strap 5011, b, c and 51 is joined together by a strong,elastomeric O-ring 78, such as an O-ring formed of high densitypolyethylene. For adjustment, each strap includes three closely spacedcircular apertures 74 at the distal ends and a single aperture 75centrally located along the length of the strap. As illustrated inFIGURE 2, the distal end of each head strap 50a, b, c and 51 is foldedback upon itself about the O-ring 78, which is common to all headstraps. Each head strap is secured about the O-ring by a stud 79 similarto the stud 68 previously described. The stud associated with each headstrap extends through the aperture 75 and through one of the threeapertures 74.

Each head strap includes an additional aperture approximately midwaybetween the head band portion and the aperture 75. See FIGURE 6. Headstraps 50a and 50c each include a circular aperture 80. Head strap 50bincludes an elongated slot aperture 81, and head strap 51 includes anelongated slot aperture 82.

In assembled condition, the head straps 500, b, c and 51 contact theoverlying legs of the first suspension at the apertures 80, 81 and 82,and are secured at those points by the studs 46. See FIGURE 2. The headstrap 50b is located at the front of the hat 10, directly underlying theleg 30a of the first suspension. Head straps 50a and 50c underlie legs30f and 30b, respectively. The single head strap 51 on the head bandpiece 48b underlies the leg 30d. The positions of the head straps 50aand 50c with respect to the legs 30 and 30!) are fixed by the smallcircular apertures 75 of the head straps and 44 of the legs, and by theconnecting studs 46. Relative longitudinal movement is permitted betweenthe front head strap 50b and leg 30a, and between the back head strap 51and leg 30d by the elongated apertures 81, 82, respectively. With thisconstruction the head band size can be adjusted without appreciabledistortion of the smooth, desired contour of the band, and withoutchanging the angular relationship between the head band and the headstraps.

During adjustment of the head band size, the relative position of thethree head straps 50a, 50b, 500 at the front of the hat remainsessentially fixed with respect to the first suspension. The smaller headband piece 48b at the rear of the hat is moved relative to the largerhead band piece. For example, to decrease the size of the head band 48,the small head band piece 48b is moved toward the front of the hat 10.The free ends of the larger head band piece 48a slide relative to theT-shaped guides 58, 59 into greater overlapping relationship with thesmaller head band piece 48b. This results in a smaller diameter headband 48. The change in size takes place behind the head straps 50a, 50c,in the back portion of the hat behind the transverse center line. Thisprevents distortion of the suspension that would occur if the change insize affected portions of the head band to which the intergral headstraps are attached. The adjustment is made equally at each end of thehead band, keeping the smaller piece 48b centered with the head strap 51directly to the rear of the hat.

As will be evident from FIGURE 2, inward or outward movement of thesmaller head band piece 48b relative to the back of the hat changes thelocation of the head band piece 48a relative to the first suspension,and particularly relative to the stud 46 extending through the headstrap 51 and the leg 30d. This change in position is accommodated by theelongated slot aperture 82 in the head strap 51. In addition to thissize adjustment, there will normally be an accompanying adjusmentnecessary in the shape of the headband in the forward portion whenplaced upon the wearers head. This is accommodated by the elongated slotaperture 81 in the front head strap 50b. A small amount of pivotalmovement of the side head straps 50a, 50c is permitted about the shanksof the studs 46 that secure the side head straps to the legs 30b, 30 ofthe first suspension.

Where large adjustments are made in the head band size, accompanyingadjustments may be necessary in the effective length of the head straps50, 51 to maintain the desired tension on the O-ring 78. This isaccomplished by placing the studs 79 through different apertures 74 toprovide the desired length.

In manufacture, the first and second suspensions can be conveniently andinexpensively molded by conventional injection molding techniques. Thetwo suspensions are easily formed and assembled by connecting the partswith the studs. Adjustments are made by merely changing the locations ofthe studs. The same suspensions will adjust to all normal sizes.Nothwithstanding the one-piece construction of the first suspension, theintegral construction of the head straps and head band of the secondsuspension, and the fixed relationship of the two suspensions at eachside of the hat, size adjustments do not distort the head band and headstraps from the desired contour.

In use, the first and second suspensions completely space the hard shell12 from the head of the wearer. Any blow received upon the top of theshell 12 is cushioned by the expansion of the elastomeric O-ring 78 inresponse to downward movement of the hat and suspensions upon thewearers head. The expansion of the O-ring 78 and head straps 50, 51 islimited by the legs 30 and circular central portion 26 of the firstsuspension, Thus, a double safeguard is provided to prevent the shell 18from coming into contact with the wearers head.

While a preferred embodiment of this invention has been described indetail, it will be apparent that many modifications or alterations maybe made therein without departing from the spirit and scope of theinvention, as set forth in the appended claims.

What is claimed is:

1. A resilient crown support for a hard shell safety hat, comprising:

(a) a first suspension formed of (i) a plurality of legs having freedistal ends and extending from a central area of interconnection, and

(ii) means at the distal ends to secure the legs to a hard shell safetyhat;

(b) a second suspension located within and beneath the first suspensionand formed of (i) a head band,

(ii) spaced straps integral with the head band and extending initiallyat essentially right angles from the head band upward toward the firstsuspension and then inward, terminating in end portions located adjacenteach other and below the central area of interconnection of the legs ofthe first suspension,

(iii) means connecting the end portions of the straps to form with thestraps a dome for engaging the head of a wearer, and

(iv) means to adjust the effective size of the head band; and

(c) means connecting straps of the second suspension to legs of thefirst suspension intermediate the ends of the strap and legs.

2. A support as defined in claim 1 wherein the legs of the firstsuspension are integral and the central area includes a circular portionfrom which the legs radiate.

3. A support as defined in claim 2 wherein the means at the distal endsof the legs includes a foot wider and thicker than the associated leg,constructed to be received in a slot in the hard shell of a safety hat,and a deformable protrusion that increases the thickness of a portion ofthe foot,

4. A support as defined in claim 3 wherein the means connecting the endportions of the straps is an endless elastomeric ring and the straps ofthe second suspension terminate in loops that loosely encircle theendless ring and which are adjustable in size to vary the effectivelength of the straps from the head band to the ring.

5. A support as defined in claim 1 wherein the head band is formed oftwo separate pieces adjustably secured together and the secondsuspension includes at least four straps, all but one of the strapsbeing located along onehalf of the length of the head band and securedto one of said two pieces and said one strap being secured to the otherof said two separate pieces.

6. A support as defined in claim 5 wherein the said one strap is locatedat the center of the said other of the two separate head band pieces andwherein both ends of each head band piece are adjustable secured to theends of the other.

7. A support as defined in claim 1 wherein the straps of the secondsupport are in contact with the legs of the first support and the strapsand legs are secured together at the locations of contact.

8. A support as defined in claim 7 including apertures in a plurality ofthe legs, apertures in each of the straps, at least one aperture of eachstrap being aligned with an aperture in a leg, and a separate fastenerpassing through the aligned apertures.

9. A support as defined in claim 1 wherein the first suspension isstronger than the second suspension and the second suspension is moreflexible than the first suspension.

10. The support as defined in claim 9 wherein the first suspension isformed of high density polyethylene and the second suspension is formedof low density polyethylene.

11. A support as defined in claim 8 wherein the head band is formed oftwo separate pieces, both ends of each head band piece are adjustablysecured to the ends of the other, all straps but one of the secondsupport are connected to one of said two separate pieces and the onestrap connected to said other of the two separate pieces isdiametrically opposite a strap of said one piece and only the two saidopposite straps each include an aperture elongated in the direction thestrap extends to receive said separate fastener and to permitlongitudinal sliding movement of the strap relative to the connected legand fastener.

12. In combination, a hard shell safety hat and a crown support for thehat, said support comprising a first suspension secured to the shell ofthe hat, a second suspension within and beneath the first suspension andsecured thereto, said second suspension having a two-piece head band andstraps extending from the band to the first suspension, all of saidstraps except one extending from one of said two pieces, the said onestrap extending from the other of said two pieces, means securing thestraps of the second suspension to the first suspension and meansadjustably securing both ends of each head band piece to the ends of theother.

13. The combination defined in claim 9 wherein the means securing thesecond suspension to the first suspension includes means to permitlimited relative sliding of the said one strap relative to the firstsuspension.

14. The combination as defined in claim 12 wherein the straps convergeafter they extend to the first suspension and are connected by anelastomeric O-ring.

15. The combination as defined in claim 12 wherein the first suspensionincludes a plurality of legs each of which includes a wider and thickerfoot portion constructed to be received in a slot in the hard shell of asafety hat and a deformable protrusion that increases the thickness of aportion of the foot.

16. A crown support for a hard shell safety hat, which comprises a firstdome-shaped suspension having a plu rality of strap-like legs thatradiate outward and downward from a central juncture, and which areconstructed to be secured at distal ends to a hard shell safety hat; asecond separate dome-shaped expansible suspension having a circular headband and head straps connected to the head band, said head straps beinginterconnected centrally of and above the head band by an elastic ring;and means connecting the head straps to legs of the first suspension,beneath and in superposed relationship with the legs so that expansionof the head straps is limited by the legs of the first suspension.

17. The support of claim 16 wherein the elastic ring is an endlesselastomeric O-ring.

18. A support as defined in claim 16 including a foot at the distal endof each leg, wider and thicker than the associated leg, constructed tobe received in a slot in the hard shell of a safety hat, and having adeformable protrusion that increases the thickness of a portion of thefoot.

References Cited UNITED STATES PATENTS 3,016,541 1/1962 ArchbOld 233,026,523 3/1962 Bowers et al. 2--3 3,175,225 3/1965 Lindblorn 2-33,221,340 12/1965 Jofife 2-3 3,205,508 9/1965 Cox 2-3 FOREIGN PATENTS998,695 7/1965 Great Britain.

JAMES R. BOLER, Primary Examiner.

zg g UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,0,260 Dated March 1969 Inventor(s) Tom W. Johns :1, Edward J. Stropkayand James D. White It is certified $1: appears in the above-identifiedpate and that said Letters fi iiefit 'fe hereby corrected as shownbelow:

Column 8, line delete "claim 9" and. substitute claim 12 SIGNED ANUSEALED NOV 1 81969 (SEAL) Attest:

Edward M. Fletcher, Jr. WILLIAM scrauym, JR.

Commissioner of Patents Attesting Officer

